Commercial & Technical Proposal For 10MW - 11 KV MWM DEUTZ Gas Engine Power Plant

www.Alborzgenerator.
com
Bargh Afshan Alborz
Quotation Number IR 245/3 - 9 pages

3 x 3.3 MW 11 kV MWM Gas Power Plant DATE: 02- September - 2011
Commercial & Technical Proposal

For
10MW - 11 kV
MWM DEUTZ Gas Engine Power Plant
Customer Name :
Project Name :
Location :
Country :
Attention to :
Contact details :
Tel: +98 121 2229599

Fax: +98 121 3239001
Web: www.AlborzGenerator.com Page 1
Email: ba_alborz@yahoo.com
www.Alborzgenerator.com
Bargh Afshan Alborz

Contents
1.0 10 MW GAS GENERATOR POWER PLANT Description

2.0 Scope of supply TBG632
3.0 Price Schedule
4.0 Terms & Condition
5.0 Documentation
6.0 Inspection
7.0 Certificate of Quality
8.0 Training
9.0 Spare Parts & Service after sale
10.0 Document negotiation
11.0 Enclosure
Tel: +98 121 2229599

Fax: +98 121 3239001
Web: www.AlborzGenerator.com
Page 2
Bargh Afshan Alborz

1.0 10mw GAS GENERATOR POWER PLANT
The Plant consists of 3 x 3.3 MWM Natural Gas Generators:
1.1 Generator Set:
Engine Model Deutz (MWM) TBG 632 V16 - Original

Continuous Power Output: 4000kVA ;3300kWe @ 25˚C
Power Derated To 3900kVA; 3120kWe @ 40°C
Engine Speed: 1000 RPM
Frequency: 50Hz
Governor Type: Electronic.
Fuel Type: Natural Gas
Fuel Consumption: 2.25 kWh / kWh
Starting: Air
Alternator Model: AVK DIG 156 I/6 or equal - Original

Brushless,
Insulation Class H, Temp Rise Class F
Automatic Voltage Regulator
Power Factor 0.8
Enclosure to IP 23 2
Bearing
Anti-Condensation Heater
Winding RTD’s (2/Phase)
Bearing RTD/’s (1/Bearing)
Metering CT’s
Differential Protection CT’s (10P20)
Rating Continuous 4125kVA, 3300kW at 40°C

Voltage: 11.0kV ±10%
Frequency: 50Hz
The Alternator comprises of a brushless two bearing unit, designed to meet the standards for industrial
rotating electrical machines laid down in BSEN60034 and relevant sections of BS5000, IECEN60034, VDE
0530, Nema MG1-22 and CSA C22.2 No. 100.
The Alternator meets the requirements of Lloyds, Germanischer Lloyd, Bureau Veritas, American
Bureau of Shipping, Det Norske Veritas or R.I.N.A.
It is of compact design, 6 pole, running at 1000 rpm, self excited with electronic Automatic Voltage
Regulator providing voltage regulation within +/- 0.5% of rated output, 6 wire stator, class H insulation, with
screen protection providing radio interference suppression to BS1597 and VDE class K, Voltage Transient
protection for AVR and rotating diodes.
Tel: +98 121 2229599 Page 3

Fax: +98 121 3239001
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2.0 Scope of supply TBG632
2.1 Basic engine TBG632 for natural gas
2.1.1 Crankcase
Single-piece casing in spherical graphite iron, inherently stable due to the depth of the side walls;
suspended main bearings, cross-bolted; lateral maintenance apertures; fitted cooling water jacket; wet
cylinder liners; crank case vented via electric extractor fan with oil separator which discharges into the open air
(supplied loose).
2.1.2 Drive gear

Forged steel crankshaft with welded counterweights, double T-shank connecting rods with inclined toothed
mating faces, single-piece light alloy piston with two compression rings, one oil wiper ring.
2.1.3 Cylinder head

Individual cylinder heads with four valves, mixture feed from V-space, exhaust directed via V-space into the
high-temperature dry PEARL exhaust manifolds. Spark plugs located centrally in the combustion
chambers with intensive plug seat cooling.
2.1.4 Ignition
Microprocessor-controlled high-tension ignition system with low-tension distribution, one ignition coil per
cylinder, with no moving parts and therefore no wear; triggered via Hall effect pick-ups at the flywheel and cam
shaft, variable ignition timing, ignition energy and distribution controlled by computer on primary side of ignition
coils, chamber type spark plugs with Teflon plug connectors.
2.1.5 Mixture formation

Air is drawn into the mixer via paper dry-air filters with visual maintenance indicator and integral air intake
preheating via the engine cooling water circuit (supplied separately); gas is supplied via the gas control unit.
Gas/air volume ratio adjusted via the DEUTZ multi-gas mixers.
2.1.6 Mixture charging

The turbocharger draws air and gas from the gas mixers at atmospheric pressure, with inter-cooling of the
compressed mixture in a 2-stage mixture cooler (low temperature stage in separate cooling circuit of 400C);
rotary throttle valve to control output is positioned after the mixture cooler.
2.1.7 Control and monitoring

The gas-air mixture is controlled via the mixer positioning motor.
Control is executed by the TEM system on the basis of a combination of combustion
chamber temperature and output/speed.
2.1.8 Compressed air starter

With attached control unit and flexible compressed air connecting hose.
Page 4
Bargh Afshan Alborz

2.1.9 Compressed air supply

We include sufficient air storage bottles and electric motor driven compressor and air supply controls, along with
a black start diesel powered compressor.
2.1.10 Lubricating oil system

Lubricating oil heat exchanger (supplied loose) for integration in the heating water or mixture cooling circuit
dependent on the layout of the plant, automatic oil replenishment into the oil pan by controlled feed from the
supply tank, automatic pre-lubrication by electric pump, same pump also used to empty the oil sump.
Bunded oil tanks both of capacity 6000 litres are included, one for clean oil and the other for waste oil.
Contents gauges and level alarms are included.
2.1.11 Cooling water connections

Expansion joints with counter flanges for inlet and outlet of jacket water and intercooler.
2.1.12 Cooling water preheating

Electric cooling water preheating 18 kW with electric circulating pump installed at the genset.
2.1.13 Radiators
Without knowing the final layout of the building we have allowed for roof mounted cooling radiators with
multiple fans for charge cooling and dump cooling.
2.1.14 Three-phase internal pole synchronous generator

As per VDE 0530, BS5000, IEC34 etc, brushless, self-regulating, self-excited, designed for island and
mains parallel operation, electronic voltage regulator and power factor regulator installed in the
terminal box, set point adjuster supplied loose for installation in a control panel, 3 x PT100
temperature sensors to monitor winding temperature, 2 x PT100 for bearing temperature
supervision, Anti-condensation heaters are fitted.
2.1.15 Genset layout

Gas engine and generator are flexibly coupled, mounted on a common steel base frame. Vibration isolation is
via spring elements for mounting on a foundation (provided by customer). Cooling water pre-heater,
pre-lubrication pump and lube oil pre-heater (with independent pump) are baseframe mounted.
2.1.16 Cabling
Genset cabled using multi-function rails. Cabling for generator and auxiliaries to be provided by
customer.
2.1.17 Paint finish

Paint colour RAL 5010.
Tel: +98 121 2229599 Page 5

Fax: +98 121 3239001
Bargh Afshan Alborz

2.1.18 HV Switchgear
Up to 13.8kV Motorised VCB - VC6 - Schneider Electric
GenieEvo metalclad switchgear panels are of the

indoor design consisting of rigid steel housings, which
comprise a non-withdrawable Vacuum circuit
breaker.
This offers a simple and flexible approach
to switchgear with a wide choice of options covering all
modern consumer applications.
The GenieEvo concept is an evolution from
the extremely successful Genie philosophy which
offers increased levels of flexibility and greater choice. By
allowing separate selection of the switchgear and
protection and control modules. GenieEvo extends the
concept of Genie by offering a gas free circuit breaker to
the product portfolio.
GenieEvo comprises
 Cast resin encapsulated MV system
 Demountable vacuum circuit breaker
 Controlled air, resin encapsulated series
disconnector
 Flexible pre-engineered protection and control
modules
Protection - Schneider Electric

‘Sepam’ protection relays offer an extensive
and modular solution for generator protection. Typical
application, protection by disconnection of the
generator, can operate in parallel with network and
conforms to engineering recommendation
G59/1 1991. Also provides differential
protection (87) of strategic generator-transformer
units. These include extensive monitoring and
control features and are ideally suited for integration
into a supervisory system.
Tel: +98 121 2229599

Fax: +98 121 3239001
Web: www.AlborzGenerator.com Page 6
Bargh Afshan Alborz

Control panels
2.2.1 DEUTZ TEM-EVO

Supplied as per separate specification for erection in proximity to the genset. Length of cable between gas
engine and TEM panel is 8 m. Panel is Rittal type AE1280, colour RAL 7032.
Intelligent terminal strip for installation in auxiliary panel (max. 250 m away from genset panel). Operating
Computer Screen with colour LCD display (max. 100 m away from genset panel), for installation in auxiliary
panel or external control panel.
2.2.2 ComAp Genset Controller panel

Each set comes with a free standing control panel fitted with the latest ComAp InteliSysNT CHP Controller.
InteliSysNT is an expandable controller for both single and multiple gen-sets operating in standby or parallel
modes, especially in cogeneration (CHP) and other complex applications.
Detachable construction requirements.(consisting of IS-NT-BB and IS-Display or InteliVision 8) allows
easy installation with the potential for many different extension modules designed to suit individual
customer
A built-in synchronizer and digital isochronous load sharer allow a total integrated solution for gen-sets in
standby, island parallel or mains parallel. Native co-operation of up to 32 gen-sets is a standard feature.
InteliSysNT supports many standard ECU types and is specially designed to easily integrate new ones.
A powerful graphic display with user-friendly controls allows any user whatever their ability to find the
information they need. The display on the basic version is capable of displaying graphical languages.
2.3 Installation parts, supplied loose
 Lubricating oil heat exchanger (plate type for mounting in LT cooling circuit)
 Electric extractor fan with oil separator for crankcase venting, including flexible connection.
Differential pressure switch for crankcase venting.
 Paper dry-air filters with integral air intake preheating and flexible air line.
Regulating valve for air intake preheating, with electric actuator.
 Expansion joints for flexible gas connection.
 Exhaust expansion joints with clips and weld-on flanges.
 Gas control unit as per DVGW supplied as a compact unit with ball valve, gas filter, manometer,
pressure switch, 2 solenoid valves, zero pressure regulator, complete with connecting flanges and
counter flanges.
1 flexible gas pipe for connection to engine.
1 set anti-vibration spring elements.
 2 solenoid valves with connectors for lubricating oil replenishment (from supply tank).
 Operating instructions and spares parts list (2 copies).
 Exhaust back pressure switch.
Page 7
Tel: +98 121 2229599
Fax: +98 121 3239001
Bargh Afshan Alborz

2.4 HV Switchgear - Transformers: 3x4500kva

HV Switchgear suite of 630A breakers, rated 11kV, 25kA for 6 sec busbar, comprising 6 generator
incomers, 2 bus section and 4 outgoing feeders
Transformers: 3x4500kva
2.5 Not included
Power plant building
Air intake and extraction
Cabling and ducting
Pipe work for gas and oil
Installation & Commissioning
3.0 Price Schedule
1 x 10 MW Power Plant, 11 kV Gas engine Power Plant and HV Switchgear as shown
Total Price { EPC } …….….. USD$ …………………………
4.0 Terms & Conditions.
Payment By confirmed irrevocable letter of credit payable in USD$ in

IRAN as follows:
30% with order,
50% when notified that goods are ready for despatch.

Part shipments to be allowed
Currency All prices are in USD$
20% after installation
Delivery
9 weeks
Validity 30 days
Origin UK
Packing Shrink-wrapped for shipping in standard shipping containers

Warranty Standard Warranty 7 Months from shipment or 5 months from date of
installation whichever is the sooner.
Page 8
Tel: +98 121 2229599

Fax: +98 121 3239001
Bargh Afshan Alborz

5.0 Documentation
One (1) Copy of the following standard set of documentation will be supplied with each Generating set:
5.1 Operating and Maintenance manual,
5.2 Wiring diagram,
All Drawings and Documentation shall be in the English language. Units of measurement shall be in
accordance with the SI or metric system.
6.0 Inspection
Inspection will be done by SGS or Lloyds and seller is obliged to coordinate for inspection and pay
inspection cost.
7.0 Certificate of Quality

The certificate of quality of the goods could be issued by Lloyds or SGS basis on the quality details and
Standard mentioned in this proposal if the Buyer require.
The seller is obliged to coordinate for issuing this certificate. The related proposal with SGS or Lloyds will sign
by the Buyer and the cost will be covered by the Buyer.
8.0 Training
Training for installation, operation and maintenance the goods for two persons from the buyer for 7 days in the
place of seller is free of charge. All costs of tickets, hotel, food and other expenses are excluded.
9.0 Spare Parts and Service after Sales

The seller is obliged to supply all spare parts and after sales services of the goods to Buyer minimum for 10
years from delivery the goods.
10.0 Document negotiation

Negotiation Documents for Letter of Credit that shall be issued or confirmed by the buyer’s Bank are
including as following:
10.1 Shipping documentation (Bill of Lading).
10.2 Certificate of Origin for all generating sets subject to this proposal.
10.3 Packing list.
10.4 Inspection certificate or report from SGS or Lloyds for all generating sets.
10.5 Certificate of warranty for all generating sets issued by the seller. 10.6
Test certificate for generating sets.
10.7 Commercial Invoice for each shipment confirmed by the local chamber of commerce. 10.8
All equipment's shall be new and made of the year 2010 and 2011 and certificate from SGS.
11.0 Enclosure
Technical data 50 Hz TBG 632 V16, Natural gas, 500 NOx ..TBG 632 V16 Erdgas 500 NOx
Technical data 50 Hz - Natural gas applications ... ..n_mwm_tbg632_0509[1]
TBG 632 V16 ... ...Schematic Plan
Page 9
Bargh Afshan Alborz
 Please find below details of what work was carried out as part of the E50 service plus the variations and testing. Hold
itch #1 - 2200071
All 16 cylinder heads replaced by service exchange cylinder heads from the Deutz German Xchange centre. All associated valve
gear re-assembled and set to the correct clearances.
All 16 combustion spaces cleaned and checked.
Both intercoolers completely stripped and rebuilt using all new gaskets and seals. All aluminium covers, top and bottom, have
been replaced using cast covers.
Both gas mixers cleaned, checked and lubricated. Control of both gas mixers checked correct and tested from the TEM with
full travel. Limit switches set up correct.
New oil filters, seals and O rings fitted.
New air filters and spark plugs have been supplied but not fitted to prevent damage in transit. Old filters and plugs re-fitted to the
engine to prevent dirt ingress to engine.
All old oil drained from engine.
Oil filter housing bracket on A bank has been replaced due to the original being badly cracked. Intercooler and jacket water
system pressure tested to 4.5 bar with no leaks.
Both turbo chargers type RR221 -14 have been returned to the manufacturer for overhaul. The details of which have been
supplied on a previous report.
New control batteries have been fitted to the generator control panel.
All associated pumps and fan motors associated with the generator have been run under electrical power
and proved correct.
Throttle has beere-calibrated through the TEM system. All engine sensors are indicating correct back to the TEM system.
The TEM CPU has been upgraded to version 2.29, and the operating terminal has been upgraded to the latest touch
screen version.
The TEM system has been re -installed with all the original commissioning parameters and additional 24 messages .
Holditch #2 - 2200093
Both gas mixers cleaned, checked and lubricated. Control of both gas mixers checked correct and tested from the TEM with
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Intercooler and jacket water system pressure tested to 4.5 bar with no leaks.
New control batteries have been fitted to the generator control pa nel and a new battery charger.
and proved correct.
Throttle has bee re-calibrated through the TEM system. All engine sensors are indicating correct ba ck to the TEM system.
screen version.
 The TEM system has been re -installed with all the original commissioning parameters and additional 24 messages
Holditch #3 - 2200100
Both gas mixers cleaned, checked and lubricated. Contr ol of both gas mixers checked correct and tested from the TEM with
Intercooler and jacket water system pressure tested to 4.5 bar with no leaks.
New control batteries have been fitted to the generator control panel.
and proved correct.
Throttle has bee re-calibrated through the TEM system. All engine sensors are indicating correct back to the TEM system.
screen version.
The TEM system has been re -installed with all the original commissioning parameters and additional 24 messages
Please find below details of the repairs carried out on each turbocharger by serial number as part of the E50 services . HT
428704, 428705, 428706,428707
Turbine casing replaced on all four above serial numbers, due to cracks which have formed in the involute section of the
Bargh Afshan Alborz
The compressor wheels have been dressed up on each of these turbo’s.
turbine casing. Large parts of the casing has broken away as a consequence on all four turbine casings.
As a result of the cracked turbine cas ing breaking away, the turbine blades have sustained foreign object damage on all four
turbochargers. This has caused an in balance resulting in excess wear to the shaft, requiring the shafts to be
replaced as a consequence on the four above turbo’s.
All four of the above turbochargers have had the normal service parts exchanged, piston rings, O seals etc. HT 428708
Turbine casing replaced due to cracks which have formed in the involute section of the turbine casing. Large parts of the casing
has broken away as a consequence on the turbine casing.
As a result of the cracked turbine casing breaking away, the turbine blades have sustained foreign object damage. The
compressor wheel has been dressed up.
The above turbocharger has had the normal service parts exchanged, piston rings, O seals etc. HT 428709
Turbine casing replaced due to cracks which have formed in the involute section of the turbine casing. Large parts of the casing
has broken away as a consequence on the turbine casing.
As a result of the cracked turbine casing breaking away, the turbine blades have sustained severe foreign object damage
which has resulted in the replacement of the compressor wheel.
The above turbocharge has had the normal service parts exchanged, piston rings, O seals etc.
Bargh Afshan Alborz
Bargh Afshan Alborz
Bargh Afshan Alborz

Commercial & Technical Proposal For 10MW - 11 KV MWM DEUTZ Gas Engine Power Plant

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Quotation Number IR 245/3 - 9 pages